Barcode Scanning Tunnel Auto-Calibration System
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Solution Overview
Problem
Existing conveyor systems with barcode scanning tunnels require complex and time-consuming calibration processes, often requiring multiple technicians and are prone to misalignment issues due to the bulkiness and heat management challenges of cameras and dimensioners, leading to inefficiencies in setup and operation.
Innovation Solution
A method for calibrating barcode scanning tunnels using a networked system with a range finder and cameras, employing calibration boxes with predefined indicia to electronically calculate camera orientations and positions relative to the conveyor belt, allowing for automated static and dynamic calibration by a single technician, reducing setup time and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional barcode scanners and dimensioners are used in conveyor systems, then barcode reading and dimensioning functions are achieved, but calibration becomes complex and time-consuming requiring multiple technicians
Solution Approach 1:
A calibration object with known geometric features and barcode is introduced as an intermediary element. This calibration object serves as a reference standard that simplifies the calibration process by providing predetermined relationships between physical dimensions and barcode positions, eliminating the need for complex multi-technician alignment procedures.
Solution Approach 2:
The calibration object is pre-configured with barcodes positioned at known distances from reference features before being introduced to the system. This preliminary preparation of calibration data allows the system to perform automated calibration by comparing captured images against the predetermined relationships, reducing calibration time and complexity.
2Ease of operation
If cameras and dimensioners are mounted in scanning tunnels, then barcode scanning capability is provided, but heat management challenges and misalignment issues occur
Solution Approach 1:
The system replaces manual mechanical alignment procedures with an automated optical calibration process. Instead of relying on physical adjustment mechanisms that are prone to drift and misalignment, the system uses image capture and processing to automatically determine and correct positioning relationships between cameras, dimensioners, and the conveyor belt.
Solution Approach 2:
The calibration process incorporates feedback mechanisms where the system captures images of the calibration object, processes the image data to determine actual positions and orientations, and uses this information to adjust or verify the positioning of scanning components. This closed-loop approach maintains alignment accuracy despite thermal expansion or mechanical drift.
3Productivity
If manual calibration by multiple technicians is performed, then initial setup is completed, but setup time is excessive and skilled labor is required
Solution Approach 1:
The calibration system performs self-calibration by automatically capturing images of the calibration object, processing the image data through algorithms, and determining the positioning relationships without requiring manual intervention from skilled technicians. The system serves itself by using its own imaging capabilities to calibrate its components.
Solution Approach 2:
The system creates a digital copy or representation of the physical calibration object through image capture. This digital model containing positional information of barcodes and reference features is then used for calibration calculations, replacing the need for physical measurement and manual configuration by technicians.
4Extent of automation
If calibration boxes with predefined indicia are used, then automated calibration is enabled, but additional components are required in the system
Solution Approach 1:
The calibration object serves multiple functions: it provides geometric reference features for camera calibration, contains barcodes for position verification, and establishes the relationship between the dimensioner and barcode scanner. This multi-functionality reduces the need for separate calibration tools and components for each function.
Solution Approach 2:
The calibration object merges several calibration elements into a single integrated component. Instead of requiring separate calibration targets for camera positioning, barcode position verification, and dimensioner alignment, all these calibration functions are combined into one object with appropriately positioned features and barcodes.
Data Source
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AI summary
A system and method for auto-calibrating a barcode scanning tunnel to determine the orientation of one or more cameras with respect to a range finder and a conveyor belt comprises providing a scanning tunnel having a moveable surface, at least one range finder having an orientation, at least one camera having an orientation and at least one calibration object having at least one indicia disposed in a predetermined relationship to one or more features of the at least one calibration object, capturing at least one image of the at least one calibration object by the at least one camera, electronically detecting the at least one calibration object at least one indicia and the one or more object features and electronically calculating at least one component of the at least one camera orientation with respect to the moveable surface in response to information obtained from the image and the at least one calibration object at least one indicia.